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    This document discusses porosity issues found in tube flanges manufactured using sand casting. Several attempts were made to work with the foundry to achieve zero porosity, including visits from C-Tech and Sandvik teams, but consistency was not achieved due to factors like moisture in the sand. Sandvik's quality standards require zero porosity while the foundry and C-Tech's acceptance criteria allow for some porosity. The porosity issues have led to increased machining times, missed delivery dates, and salvaging costs through porosity welding. C-Tech has taken several corrective actions to address other recent challenges in manufacturing Sandvik's components.

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    This document discusses porosity issues found in tube flanges manufactured using sand casting. Several attempts were made to work with the foundry to achieve zero porosity, including visits from C-Tech and Sandvik teams, but consistency was not achieved due to factors like moisture in the sand. Sandvik's quality standards require zero porosity while the foundry and C-Tech's acceptance criteria allow for some porosity. The porosity issues have led to increased machining times, missed delivery dates, and salvaging costs through porosity welding. C-Tech has taken several corrective actions to address other recent challenges in manufacturing Sandvik's components.

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    15 views14 pages

    Updated Sandvik Presentation

    Uploaded by

    Compdevp
    This document discusses porosity issues found in tube flanges manufactured using sand casting. Several attempts were made to work with the foundry to achieve zero porosity, including visits from C-Tech and Sandvik teams, but consistency was not achieved due to factors like moisture in the sand. Sandvik's quality standards require zero porosity while the foundry and C-Tech's acceptance criteria allow for some porosity. The porosity issues have led to increased machining times, missed delivery dates, and salvaging costs through porosity welding. C-Tech has taken several corrective actions to address other recent challenges in manufacturing Sandvik's components.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Flag for inappropriate content
    of 14

    C-Tech Engineers Pvt. Ltd.

    Sandvik Cell Challenges


    And Actions

    18/08/2021
    C-Tech Engineers Pvt. Ltd.

    Tube Flanges having Porosity Problems


    C-Tech Engineers Pvt. Ltd.

    Tube Flanges having Porosity Problems


    C-Tech Engineers Pvt. Ltd.

    Causes and Analysis Porosity

    A. Achieving zero porosity with sand casting method is difficult.

    B. So many times we had discussed with Foundry people and visited to monitor the process.

    C. Even Sandvik Team also had been to Kolhapur, then one or two lots are ok but no consistency achieved.

    D. Due to Moisture in sand porosity increases.


    C-Tech Engineers Pvt. Ltd.

    Difficulties while working with foundry people

    • Due to heavy Rejection it is very difficult to work with foundry people.

    • They are not interested to work for Zero porosity with present rates.
    C-Tech Engineers Pvt. Ltd.

    Standards Given by Sandvik for worst case of acceptance


    C-Tech Engineers Pvt. Ltd.

    Standards Given by Sandvik for worst case of acceptance


    C-Tech Engineers Pvt. Ltd.

    Standards Given by Sandvik for worst case of acceptance


    C-Tech Engineers Pvt. Ltd.
    Criteria / Standards for Acceptance

    • Though it is specified in standard and Foundry has requested acceptance according to the standard.

    • And also our Machining Partner (Sister Concern)has been requested for acceptance according to standard.

    • Sandvik Quality department has been not approved the acceptance according to the standard.

    • Sandvik wants zero porosity.


    C-Tech Engineers Pvt. Ltd.

    Late Deliveries

    • It is very difficult to achieve zero porosity.

    • Average porosity observed minimum 20 pin holes for one flange, that means minimum 40 holes

    per pipe.

    • The machining time is increased from 02 to 05 times due to salvage of porosity.

    • For salvaging the porosity issue machinist has to take the assembled pipe down from the

    machine for porosity welding process.

    • Porosity rework affects machining of the other components leads to delivery date failure.
    C-Tech Engineers Pvt. Ltd.

    Quotation from Supertech for salvage of Porosity


    C-Tech Engineers Pvt. Ltd.

    Other Challenges in last 6 months And Corrective Actions

    Sr.no Challenges Corrections


    1 Operator Unavailability on Shri yantra CNC M/C due Skilled operator with ITI qualification and 10-12 Years experienced has
    to Covid been recruited and trained on the M/C.
    2 Turnover of quality persons due to pandemic Experienced quality person has been recruited for Pre Dispatched
    inspection.
    3 Delayed in casting supply due to rate revision and heavy Discussed with foundries ,visit has been arranged and rate revised by C-
    rain in Kolhapur. Tech.
    4 Rejection of bearing housing on Shri yantra due to ID Work instructions has been prepared to control the ID on M/C
    Oversized by 30-40 microns. training has been imparted to the operators
    5 Gas Cut material was not available due to shortage of Now the supply is smooth and we have been continuously monitoring.
    oxygen in pandemic.
    6 Stock removal of Sandvik components is more on M/C. Semi finish operation for some components has been out sourced to
    improve the delivery.

    7 Existing supplier was not ready for the machining of So we have change the supplier and get it done from new supplier.
    Head nut.
    C-Tech Engineers Pvt. Ltd.

    Work Instruction for Shri Yantra machine


    C-Tech Engineers Pvt. Ltd.

    Thank You

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